Concrete forming system

ABSTRACT

A concrete forming system for pouring concrete walls or slabs. As applied to a wall construction, the forming system includes a pair of spaced interconnected wall sections with the space between the walls adapted to receive the poured concrete. Each wall section comprises a facing panel supported by a series of vertical truss assemblies which are spaced at intervals along the length of the facing panel. Each truss assembly includes a pair of spaced chord members which are interconnected by a diagonal truss member and the panel is fastened to one of the chord members. Reinforcing and alignment for wall section is provided by a series of channel walers, with each waler consisting of a pair of spaced channels. Ties are disposed between the channels of each waler and serve to interconnect the wall sections.

Umted States te 1 [111 3,905,574

Brauer Sept. 16, 1975 CONCRETE FORMING SYSTEM 4 Primary Examiner-Francis S. Husar [75] Inventor. Robert C. Brauer, Wauwatosa, Wls. Assistant Examiner john S Brown [7 A signe OBrien & Br r C n r i n, Attorney, Agent, or FirmAndrus, Sceales, Starke &

lnc., Brookfield, Wis. Sawall 22 Filed: Mar. 13, 1973 [57] ABSTRACT [21] Appl. No.: 340,697

A concrete formmg system for pounng concrete walls or slabs. As applied to a wall construction, the forming [52] US. Cl 249/45; 249/191 system includes a pair of spaced interconnected wall (31-2 E046 6 17/06 sections with the space between the walls adapted to Field of Search receive the poured concrete. Each wall section com- /19l, 8 prises a facing panel supported by a series of vertical 30, 219 219 truss assemblies which are spaced at intervals along 376 the length of the facing panel. Each truss assembly includes a pair of spaced chord members which are in- [56] References C t terconnected by a diagonal truss member and the UNITED STATES PATENTS panel is fastened to one of the chord members. Rein- 557,147 3/1896 Rapp 52/376 forcing and alignment for Wall Section is Provided by 3 1,780,661 11/1930 wedberg" series of channel walers, with each waler consisting of 1,380,453 10/1932 Kamzlerm a pair of spaced channels. Ties are disposed between 2,055,977 9/1936 Hayes 249/192 X the channels of each waler and serve to interconnect 2,288,365 6/1942 Moths 249/210 the wall sections, 2,641,043 6 1953 Martin 249/34 x 2,851,747 9/1958 Rolen 52 376 x 9 Clams 6 Drawmg Flgures PATENT SEP 1 6 W5 SHEET 1 [IF 2 REE? 2 UP 2 CONCRETE FORNIING SYSTEM BACKGROUND OF THE INVENTION In the pouring of concrete walls, slabs, and other structural members, various forms are utilized. When pouring concrete walls the forms include spaced wall sections which define a space within which the concrete is poured. In conventional forming systems, wall sections are connected together by a series of ties and after pouring of the concrete and removal of the forms, the ends portions of the ties that extend outwardly from the poured wall are removed or broken off and the resulting holes in the poured concrete wall are patched.

The dimensions of the wall determine the number of ties to be utilized and with walls of substantial height, a large number of ties are employed which not only requires considerable labor in assembly, but also in removal and patching of the wall after the forms have been removed.

In smaller construction jobs, the forms are usually individually assembled for pouring and disassembled after pouring, while in larger jobs, gang forms may be utilized in which the forms, after removal are moved as a unit to another location at the site for the pouring of a second wall section or slab. Most wooden forms do not lend themselves to gang operation. Steel forms, on the other hand, while lending themselves to gang operation are heavy and difficult to handle, transport and erect.

SUMMARY OF THE INVENTION The present invention is directed to an improved concrete forming system utilizing relative lightweight, inexpensive forms which are easily assembled, transported and stored.

The concrete forming system as utilized in forming a vertical concrete wall includes a pair of horizontally spaced interconnected wall sections with the space between the wall sections adapted to receive the poured concrete. Each wall section is composed of an inner facing member or panel supported by a series of vertical truss assemblies which are spaced at intervals along the length of the panel. Each truss assembly includes a pair of spaced chord members which are interconnected by a diagonal truss member and the panel is nailed or otherwise fastened to one of the chord members.

Reinforcing and alignment is provided for each wall section by a series of channel-walers with each waler consisting of a pair of spaced horizontal channels. Ties are disposed between the channels of each waler and serve to interconnect the wall sections together.

The forming system of the invention has improved versatility and can be utilized to form vertical walls, slabs or other types of structural members. The sections are preferably assembled in a number of different sizes which can be combined in any desired manner depending on the dimensions of the wall or slab to be poured. The sections can be either hand-set individually when pouring smaller walls or slabs, or can be utilized in gang form in which an entire assembly of sections can be moved from one pouring site to the next.

The truss assemblies provide optimum reinforcement for the sections and reduce the number of ties which are necessary as compared to conventional forming systems. By minimizing the number of ties, the cost of assembly is substantially reduced and the finishing costs are correspondingly reduced. Furthermore, the use of the forming system of the invention minimizes panel marks on the poured concrete, thereby resulting in a more uniform surface for the poured concrete wall or slab. v

The forming sections are economical to produce and are light in weight compared to conventional metal forming sections so that they can be readily handled, transported, assembled and disassembled with minimum effort.

Other objects and advantages will appear in the course of the following description.

DESCRIPTION OF THE DRAWINGS The drawings illustrate the best mode-present contemplated of carrying out the invention.

In the drawings:

FIG. 1 is a side elevation of the forming system of the invention as utilized in forming a vertical wall;

FIG. 2 is an enlarged section taken along line 22 of FIG. 1;

FIG. 3 is a section taken along 3--3 of FIG. 1 and showing the attachment of the channel waler to the truss assembly;

FIG. 4 is a section taken along line 4-4 of FIG. 2;

FIG. 5 is a side elevation of a modified form of the invention in which the forming system is utilized in forming a horizontal slab; and

FIG. 6 is a top view of the structure shown in FIG. 5 with parts broken away.

DESCRIPTION OF THE PREFERRED EMBODIMENT FIGS. 1-4 illustrate the concrete forming system of the invention as utilized in forming a vertical wall. The forming system includes a pair of wall section 1 and 2 which are supported in spaced relation on a concrete footing 3. The wall sections 1 are connected together at their upper, lower and central portions by tie assemblies 4. Prior to pouring the concrete, suitable reinforcement, such as reinforcing rods, is positioned in the space between the wall sections 1 and 2 and the concrete is subsequently poured around the reinforcement to form the wall.

A pair of wood plates 5 are nailed in spaced relation to the footing 3 and serve as aligning guides for the erection of the wall sections 1 and 2.

Each of the wall sections 1 and 2 is formed of a plywood or other smooth surfaced panel 6, which is supported at intervals along its length by a series of vertical truss assemblies 7. Each truss assembly 7 includes an inner vertical support or chord 8, which, as best shown in FIG. 4, includes a pair of flat surfaces 9 that bear against the inner surface of the panel 6. The central portion of each support 8 is bent outwardly in a generally U-shapebend 10 to provide a vertical slot 11 between the two flat surfaces 9.

To secure the panel 6 to the supports 8, fasteners such as serrated nails 12 are driven through the panel and into the slot 11 in the support 8.

Each truss assembly 7 also includes an outer support or chord 13 which is located in generally parallel relation to the support 8 and a truss 14 is secured between the two supports 8 and 13.

The drawings illustrate the truss 14 as being a series of zig-zag or diagonal members which can .be either formed of bar stock or hollow tubing. However, the truss 14 can take other forms.

Outer support 13, as illustrated in FIG. 4, has a generally hat-shaped cross section and the truss 14 is welded to the central portion 15 of the outer support 13.

Added rigidity is provided for the ends of the truss assemblies by stiffeners 16 which are welded between the supports 8 and 13 and to the ends of the truss members 14.

As best illustrated in FIG. 2, the panels 6 and supports 8 and 13 do not extend continuously the full height of the wall, but instead are discontinuous with a gap 17 between the members which serves to receive the central tie assemblies 4. The adjacent edges of the outer supports 13 can be connected together by a channel-shaped connector 18 which is secured to the respective ends of the supports 13 by bolts 19. Connectors 18 serve to maintain vertical alignment of the upper and lower sections of each truss assembly.

To provide additional rigidity for each wall section, a channel waler unit 20 is secured to each wall section in alignment with the gap 17. Similar channel waler units 21 and 22 are secured to the upper and lower ends, respectively, of the supports 8.

As best illustrated in FIG. 3, each channel waler unit is composed of a pair of horizontal channels 23 and 24 which are spaced apart at intervals throughout their length by spacers 25. Bolts 26 extend through openings in the spacers and serve to connect the channels 23 and 24 together.

To connect the waler units to the supports 8, bearing plates 27 are secured to the outer surface of the bent portion 10 of the support and the flanges of the channels 23 and 24 bear against the plate 27.

Bolts 28 extend through aligned openings in the channel flanges, plate 27 and bent portion 10 and are threaded in nuts 29 secured to the inner surface of the bent portion 10 of the support 8. With this construction the waler units 20, 21 and 22 extend continuously along the length of each wall section to provide support for the section. As shown in FIG. 2, one central waler channel unit is utilized, but the number and disposition of the waler units will depend on the dimensions of the wall being poured.

The wall sections 1 and 2 are connected together by the tie assemblies 4 which extend within the gap 17 between the panels 6. Each tie assembly includes a tie rod 30 which extends within the space between the channels 23 and 24 of the respective waler unit. The ends of the tie rod 30 receive washers 31 and nuts 32.

The portions of the gap 17 extending between the tie rods 30 can be enclosed by a board 33, such as a 2 X 6. The inner edge of the board 33 is substantially flush with the inner surface of the panel 6 so that the board 33 prevents the concrete from leaking through the gap 17 to the exterior.

To prevent the upper ends of the wall sections from being displaced inwardly, a series of spacers 34 are positioned at intervals along the top of the wall sections and extend between the flanges on the channels 23 of the upper waler units 21.

To erect the forms, as shown in FIGS. 1-4, the wood plates 5 are initially secured in proper position to the footing and one of the wall sections 1 or 2 is normally assembled when lying horizontally on the grade. After assembly, the wall section 1 is erected to a vertical position and braced and reinforcement is then located in the proper position adjacent the panel 6 and above the footing 3. After the reinforcing rods or other reinforcement has been positioned, the second wall section 2 is erected into position and connected to wall section 1 by attachment of the tie assemblies 4.

FIGS. 5 and 6 illustrate a modified form of the invention in which the forming system is utilized to form a concrete slab or deck. As utilized in this application, the forming system includes a series of slab or deck sections 35, with each section including a panel 36 similar to the panel 6 of the first embodiment. Each panel 36 is reinforced by a series of generally parallel spaced truss assemblies 37, similar in structure to the truss assemblies 7 of the first embodiment. Each truss assembly 37 includes an upper support 38, a lower support 39 and a truss member 40 which interconnects the supports 38 and 39. The adjacent ends of the lower supports 39 of adjacent sections can be connected together by a connector 41 which is bolted to the supports 39, similar to the manner in which the connector 18 is utilized in the first embodiment.

The slab sections 35 are supported by a series of adjustable shores or colurrms 42, the lower ends of which are supported on grade or on a suitable foundation. The upper end of each shore 42 is provided with a flange 43 and a pair of parallel plates 44 extend upwardly from the flange. A dimensional lumber board 45, such as a 2 X 6 or 2 X 8, is positioned within the space between the plates 44 and extends between a series of the shores 42.

As shown in FIG. 5, channels 46 are positioned on the outer surfaces of the plates 44 and are connected through the board 45 by bolts 47.

As in the case of the first embodiment, bearing plates 48 are secured to the lower surface of the upper support 38 and bearing plates 48 rest on the upper flanges of the channels 46 so as to support the truss assemblies 37 from the shores 42.

As the upper surface of the board 45 is spaced beneath the upper surface of the panels 36, a spacer 49 can be located above the board 45 to provide a substantially continuous flush surface for pouring of the concrete on the panel 36.

The slab section 35 can be individually hand set or assembled in gang form in which the entire gang is moved into position by elevation of the adjustable shores 42. In some operations after pouring of the concrete, it may be possible to remove the truss assemblies 37 for use in a second pouring operation, while maintaining the slab supported by the shores 42 and board 45. In other applications the entire system can be removed as a gang after the concrete has set and moved to another pouring site.

The forming system of the invention has improved versalility over conventional systems and can be used to pour vertical concrete walls, horizontal slabs, or any other type of structural members. The wall or slab sections can be connected together in various arrangements or combinations so as to provide a forming system that can be utilized for walls or structural members of any dimension. As a further advantage, the sections can be either hand set or can be used in gang form in which a series of sections are interconnected and moved from site to site as a gang. The wall and slab sections are lightweight and can be readily handled, transported and stored.

The use of the truss assemblies provide a low cost, effective means of reinforcement for supporting the panels thereby minimizing the number of ties that are required when pouring vertical walls. As the number of ties are reduced, the cost of assembling and disassembling the forms is substantially reduced and the finishing costs for the concrete wall are similarly reduced.

For walls of smaller heights, the central tie assemblies can be eliminated with the result that the poured wall will require no tie patching, thereby resulting in a more uniform and asthetically pleasing concrete surface.

In the embodiment of FIGS. 14, the truss assemblies 7 are tie assemblies do not have to be located in any particular relationship, and the tie assemblies can either be aligned with the truss assemblies or located be tween truss assemblies. Similarly in the embodiment of .FIGS. 5 and 6, the truss assemblies do not have to be in any specific relationship with respect to the shores 42.

I claim:

1. In a concrete forming system, a pair of panels having adjacent edges spaced apart to provide an elongated gap therebetween, a series of truss assemblies secured edgewise to the outer surface of each panel and extending generally normal to said gap, the ends of said truss assemblies terminating adjacent said gap, and reinforcing means disposed generally parallel to said gap, said reinforcing means comprising a pair of spaced reinforcing members, with one of said reinforcing members being secured to the truss assemblies associated with one of said panels and the other of said reinforcing members being secured to the truss assemblies associated with the other of said panels, the space between said reinforcing members being aligned with said gap.

2. The system of claim 1, wherein the panels are disposed vertically in a substantially common plane and the system includes a plurality of tie members extending through said gap and adapted to connect the panels to a second pair of generally parallel panels.

3. The system of claim 2, and including a spacer member disposed within the gap and extending horizontally between adjacent tie members, the inner surface of said spacer member being substantially flush with the inner surface of said panel.

4. The system of claim 1, wherein said reinforcing members are back-to-back channels, and said system includes connecting means disposed at spaced intervals along the length of the channels to secure the channels together.

5. The system of claim 1, and including a connecting member extending across the gap for connecting adjacent ends of said truss assemblies together.

6. The system of claim 1, wherein said panels are vertical and said system includes a second pair of panels disposed in edge abutting relation to each other, said second pair of panels disposed in spaced parallel relation to said first pair of panels, said system also including a plurality of tie members connecting said first and second pairs of panels together.

7. The system of claim 1, wherein each truss assembly includes a first support member disposed in engagement with the outer surface of the panel, a second support member disposed in spaced parallel relation to the first support member, and a truss member connecting said first and second support members, said reinforcing members being connected to the outer surface of said first support members.

8. The system of claim 7, wherein said first support member includes a pair of generally flat side surfaces disposed in engagement with the outer surface of the panel and a central outwardly bent portion extending between said side surfaces, said reinforcing members being secured to the outwardly bent portions of said first support members.

9. The system of claim 1, wherein said panels are horizontal, and said system includes a plurality of vertical supports secured to said reinforcing members.

UNITED STATES PATENT AND TRADEMARK OFFICE CERTIFICATE OF CORRECTION Q PATENT NO. 3,905,574

DATED September 16 1975 mv morus) ROBERT C. BRAUER It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Col. 5 Line 13 Cancel "are" and substitute therefor -and---- Col. 5 Line 19 Before "I Claim'z' insert the following paragraph -Various modes of carrying out the invention are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter which is regarded as the invention.--

. Signed and Scaled this twentyev h Day of January 1976 [SEAL] Attest:

RUTH C. MASON C. MARSHALL DANN Arresting Officer Commissioner nfPatenrs and Trademarks 

1. In a concrete forming system, a pair of panels having adjacent edges spaced apart to provide an elongated gap therebetween, a series of truss assemblies secured edgewise to the outer surface of each panel and extending generally normal to said gap, the ends of said truss assemblies terminating adjacent said gap, and reinforcing means disposed generally parallel to said gap, said Reinforcing means comprising a pair of spaced reinforcing members, with one of said reinforcing members being secured to the truss assemblies associated with one of said panels and the other of said reinforcing members being secured to the truss assemblies associated with the other of said panels, the space between said reinforcing members being aligned with said gap.
 2. The system of claim 1, wherein the panels are disposed vertically in a substantially common plane and the system includes a plurality of tie members extending through said gap and adapted to connect the panels to a second pair of generally parallel panels.
 3. The system of claim 2, and including a spacer member disposed within the gap and extending horizontally between adjacent tie members, the inner surface of said spacer member being substantially flush with the inner surface of said panel.
 4. The system of claim 1, wherein said reinforcing members are back-to-back channels, and said system includes connecting means disposed at spaced intervals along the length of the channels to secure the channels together.
 5. The system of claim 1, and including a connecting member extending across the gap for connecting adjacent ends of said truss assemblies together.
 6. The system of claim 1, wherein said panels are vertical and said system includes a second pair of panels disposed in edge abutting relation to each other, said second pair of panels disposed in spaced parallel relation to said first pair of panels, said system also including a plurality of tie members connecting said first and second pairs of panels together.
 7. The system of claim 1, wherein each truss assembly includes a first support member disposed in engagement with the outer surface of the panel, a second support member disposed in spaced parallel relation to the first support member, and a truss member connecting said first and second support members, said reinforcing members being connected to the outer surface of said first support members.
 8. The system of claim 7, wherein said first support member includes a pair of generally flat side surfaces disposed in engagement with the outer surface of the panel and a central outwardly bent portion extending between said side surfaces, said reinforcing members being secured to the outwardly bent portions of said first support members.
 9. The system of claim 1, wherein said panels are horizontal, and said system includes a plurality of vertical supports secured to said reinforcing members. 